Fuel compositions containing sulfur-bridged phenolic antioxidants

ABSTRACT

Fuel compositions contain a liquid, sulfur-bridged, hindered phenol antioxidant composition prepared by reacting a mixture of hindered phenols with a sulfur chloride in the presence of a polar modifier.

This application is a division of application Ser. No. 389,329, filedAug. 3, 1989 now U.S. Pat. No. 4,946,610.

BACKGROUND OF THE INVENTION

This invention relates generally to sulfur-bridged phenols useful asantioxidants and more specifically to the preparation of a liquid,sulfur-bridged, hindered phenol composition which is an effectiveantioxidant in lubricating oils without causing excessive coppercorrosion.

The antioxidant use of hindered, sulfur-bridged phenols having abranched alkyl group on the alpha carbon atom and made by reacting thephenol with sulfur dichloride in a solvent with recovery of acrystalline product from the reaction mixture is disclosed in U.S. Pat.No. 3,250,712. The preparation of a crystalline4,4-thiobis-(2,6-di-t-butylphenol) product by reacting the phenol with asulfur halide in a solvent such as acetonitrile, carbon disulfide orcarbon tetrachloride with or without a catalyst followed by treating thereaction mixture with alkali hydroxide in alcohol is disclosed in U.S.Pat. No. 3,678,115. The preparation of a liquid lubricant oil additivemixture of 45-75 wt % ortho-alkylphenol and certain amounts of mono, di,tri and tetrasulfides of the phenol by the reaction of an excess of thephenol with sulfur using an organic amine catalyst is disclosed in U.S.Pat. No. 3,929,654. It is also reported in this patent that sulfurizedalkylphenols prepared by reacting an alkylphenol with sulfur mono- ordichloride tend to cause copper corrosion probably due to the presenceof corrosive sulfur species such as sulphochlorinated alkylphenol.

BRIEF SUMMARY OF THE INVENTION

We have now prepared a liquid mixture of hindered, sulfur-bridgedphenols with good oil solubility, compatibility, antioxidant and coppercorrosion properties using a sulfur chloride for sulfurization.

In accordance with this invention there is provided a liquid,sulfur-bridged, hindered phenol product prepared by the processcomprising reacting a liquid mixture of phenols containing at least twohindered phenols, each phenol having at least one hydrogen in the orthoor para position, with a sulfur chloride, in amounts of from about 0.45to 0.55 mole of sulfur chloride per mole of phenol, in the presence ofan amount of polar modifier which is effective to reduce the coppercorrosion properties of said product and recovering the liquid,sulfur-bridged, hindered phenol product.

Also provided are lubricating and fuel compositions comprising a majoramount of a fuel or oil of lubricating viscosity and an antioxidantamount of the above liquid, sulfur-bridged, hindered phenol product.

DETAILED DESCRIPTION

An advantage of this invention is the liquid nature of thesulfur-bridged, alkylphenol product which facilitates its handling anddissolving in fuels, lubricating oils and other oxygen sensitivematerials. The initial phenol mixture to be sulfurized should contain atleast two different hindered phenols each having at least one hydrogenin the ortho or para position in proportions to provide a liquid productat ambient temperatures (20° C. -25° C.) from which solid material willnot separate on standing. By hindered phenol is meant that the phenol issubstituted in at least one ortho position with a branched chain C₃ toC₁₂ alkyl group and preferably a C₄ -C₆ alkyl group. Examples ofsuitable ortho-alkylphenols include:

2-tert-butylphenol

2,6-di-tert-butylphenol

2,4-di-tert-butylphenol

2-isopropylphenol

2,6-diisopropylphenol

2,4-diisopropylphenol

2-sec-butylphenol

2,6-di-sec-butylphenol

2,4-sec-butylphenol

2-tert-hexylphenol

2,6-di-tert-hexylphenol

2-tert-butyl-p-cresol

2-tert-butyl-o-cresol

2-tert-dodecylphenol

2-tert-dodecyl-p-cresol

2-tert-decyl-o-cresol

2-tert-butyl-6-isopropylphenol

Suitable mixtures contain up to about 95 weight percent of each reactivehindered phenol with the remainder being one or more different phenols.Normally two reactive hindered phenols are each present in at leastabout 5 weight percent. By a reactive phenol is meant a phenol having atleast one hydrogen in the ortho or para positions to the hydroxyl group.The mixture preferably contains at least about 50 weight percent, andmost preferably at least about 75 weight percent, of a di-ortho,branched chain alkylphenol such as 2,6-di-tert-butyl phenol. The mixturecan also contain minor amounts of up to about 25 weight percent of2,4,6-trialkyl substituted phenols which are not sulfurized in thereaction.

The phenol is reacted with either sulfur mono- or dichloride in amountsof from about 0.45 to 0.55 mole per mole of reactive hindered phenols inthe mixture in the presence of a polar modifier. By polar modifier ismeant a normally liquid organic compound containing at least one polarsubstituent which compound does not react with sulfur chloride orotherwise decompose under the reaction conditions but does act to changethe sulfurized phenolic product mixture such that the product is lesscorrosive to copper. Examples of such compounds include acetonitrile,nitromethane, formamide and nitrobenzene. The modifier should be presentin an sufficient amount which is effective to reduce the coppercorrosion properties of the product to an ASTM D-130 test value of orbetter and also avoid the formation of any significant deposit on thecopper. Above about 10 wt percent and, preferably, from about 15 to 150weight percent of modifier based on the weight of phenol in the reactionmixture, is used. The use of larger amounts of modifier is not necessaryand excessive amounts, which cause the formation of sufficient mono anddithio bridged crystalline products to interfere with the liquid natureof the product, should be avoided. Mixtures of polar modifiers can beused. The reaction is exothermic and the reaction temperature ispreferably kept at from about 15° C. to 70° C. (most preferably fromabout 35° C. to 55° C.) by controlling the rate of sulfur chlorideaddition to the phenolic mixture which usually takes from about 1 to 3hours. Heat may be added to finish the reaction and keep the temperaturewithin the preferred range. Higher or lower temperatures can be used solong as the reaction is completed without decomposing the product orproducing a significant amount of side products.

After the reaction is completed, the modifier is removed, preferably byvacuum distillation. A diluent oil or solvent such as toluene, xylene orthe like can be added to the remaining product mixture and the productmixture filtered to remove any solids. Usually from about 5 to 25 wtpercent diluent oil is used.

The liquid antioxidant product includes, depending upon the phenols inthe initial mixture, mixtures of sulfur bridged bis and/or polyphenolcompounds such as are represented by the formulae I and II; ##STR1##

The amount of unreacted phenols which contain an ortho or para hydrogenis less than about 20 weight percent.

The products are added to lubricating compositions or liquid organicfuels in antioxidant effective amounts which generally range from about0.05 to 5.0 wt percent, and preferably 0.1 to 2.0 wt percent, based onthe total weight of composition.

The products can be added to the oil or fuel in the form of additiveconcentrates usually containing a diluent oil or solvent and otheradditives. The amount of product in the concentrates will generally varyfrom about 0.5 to 50 weight percent or more.

Lubricating composition base stock oils include natural and syntheticoils having viscosities which generally range from about 2.5 to 12 cpsat 100° C. depending upon the particular lubricant application. Thecompounds of the invention are especially useful in crankcase lubricantswhere they act as antioxidants and reduce sludge formation.

Advantageous results also are achieved by employing the antioxidantadditives of the present invention in base oils conventionally employedin and/or adapted for use as power transmitting fluids such as automatictransmission fluids, tractor fluids, universal tractor fluids andhydraulic fluids, heavy duty hydraulic fluids, power steering fluids andthe like. Gear lubricants, industrial oils, pump oils and otherlubricating oil compositions can also benefit from the incorporationtherein of the additives of the present invention.

The additives of the present invention may be suitably incorporated intosynthetic base oils such as alkyl esters of dicarboxylic acids,polyglycols and alcohols, polyalphaolefins, alkyl benzenes, organicesters of phosphoric acids, polysilicone oils, etc.

Natural base oils include mineral lubricating oils which may vary widelyas to their crude source, e.g., whether paraffinic, naphthenic, mixed,paraffinic-naphthenic, and the like; as well as to their formation,e.g., distillation range, straight run or cracked, hydrorefined, solventextracted and the like.

More specifically, the natural lubricating oil base stocks which can beused in the compositions of this invention may be straight minerallubricating oil or distillates derived from paraffinic, naphthenic,asphaltic, or mixed base crudes, or, if desired, various blends oils maybe employed as well as residuals, particularly those from whichasphaltic constituents have been removed. The oils may be refined byconventional methods using acid, alkali, and/or clay or other agentssuch as aluminum chloride, or they may be extracted oils produced, forexample, by solvent extraction with solvents of the type of phenol,sulfur dioxide, furfural, dichlorodiethyl ether, nitrobenzene,crotonaldehyde, molecular sieves, etc.

The compositions of the invention can also be employed in gasolinegasohol and in middle distillate fuels such as diesel fuel, furnace oiland jet fuel.

The invention is further illustrated by, but is not intended to belimited to, the following examples wherein parts and percentages are byweight unless otherwise indicated.

EXAMPLE 1

A 4-neck reactor was equipped with a mechanical stirrer, condenser,thermometer and addition funnel. The off-gas outlet of the condenser wasconnected to a HCl scrubber containing an aqueous NaOH solution. Acharge of 937.0 grams of a phenolic mixture containing about 75 wt %2,6-di-tert-butyl phenol, 2 wt % 2,4-di-tert-butyl phenol, 10%ortho-tert-butyl phenol and 13% 2,4,6-tri-tert-butyl phenol and 235.6grams (25 wt percent) of acetonitrile was placed in the reactor andagitation started. The S₂ Cl₂, 279.0 grams, was added dropwise over aperiod of about 1.5 hours. The temperature rose due to the exotherm to47° C. After the S₂ Cl₂ addition was completed the reaction mixture wasmaintained at about 55° C. with heating for 0.5 hour. The temperaturewas then raised to 70° C. to vacuum distill the acetonitrile with thebatch held under full vacuum (30-50mm Hg) for 1 hour. The vacuum wasbroken and 120 grams of process oil #5 were added to the product and theproduct was filtered to remove a small amount of crystalline materialwhich was formed in the reaction. The product contained 10.9 wt percentsulfur and 1.3 wt percent chlorine.

COPPER CORROSION TEST (D-130)

Lubricant compositions of a fully formulated 5W-30 crankcase lubricantoil containing 0.75 and 1.2 weight percent of the product prepared inExample I were tested in the D-130 test at 121° C. for 3 hours.

This test indicates the resistance of the lubricant to corrosion ofcopper. A freshly refinished copper strip is placed in a 1×6 in.(25.4×152.4 mm.) test tube with 25 grams of the oil being tested. Thetube is placed in a heated bath for the proper period of time. Afterremoval from the bath, the condition of the strip is compared with a setof standard strips and given a rating according to the standard stripmost closely matched. The ratings ranged from 1 to 4 with letters a to dfor intermediate ranges.

The results are reported in Table I below along with a comparisonlubricant containing a product prepared according to Example 1 exceptthat no acetonitrile modifier was used, the distillation strip step wasreplaced by a 30 minute nitrogen purge followed by a 30 minute vacuumstrip and the product was not filtered.

                  TABLE I                                                         ______________________________________                                        D-130 Copper Corrosion                                                        Additive     Product of Ex 1                                                                           Comparison                                           ______________________________________                                        0.75 wt %    lb          4a                                                   1.20 wt %    lb          --                                                   ______________________________________                                    

From the results reported in Table I, the product of the invention gaveacceptable copper corrosion results whereas the product prepared withoutthe solvent caused severe copper corrosion.

EXAMPLE 2

To a 500 mL reactor were added 90.0 grams of the phenolic mixtureaccording to Example 1 and 45.1 grams (50 wt %) of CH₃ CN and themixture was heated to 50° C. S₂ Cl₂ (26.8 grams) was added slowly over aperiod of 1 hour and 10 minutes. The resulting batch was held at 50° C.under a N₂ sweep for 1 hour. The acetonitrile was then removed by vacuumstripping to give a dark brown viscous product (106.4 grams), (analysis:12.9% S).

EXAMPLE 3

To a 250 mL reactor were added 90.8 grams of the phenolic mixtureaccording to Example 1 and 45.1 grams (50 wt %) CH₃ CN and to themixture were added 27.0 grams of S₂ Cl₂ dropwise at 23° C. over a periodof about 40 minutes. The batch temperature peaked at 42° C. and nofoaming occurred. The resulting batch was heated at 55° C. for 30minutes followed by vacuum distillation of the acetonitrile. The batchtemperature was gradually allowed to go up to 70° C. A crystalline solidwas seen forming over the batch surface level. After vacuum stripping at70°-75° C. for 1 hour, the batch (105 grams) was diluted and filteredthrough a Whatman No. 54 paper to give a 90% active, clear, amberviscous liquid with process oil #5 (11.7 grams) (analysis: 11.4% S,1.27% Cl).

EXAMPLE 4

To a 500 mL reactor were added 37.5 grams of 2,6-di-t-butylphenol, 51.5grams of o-t-butylphenol and 45 grams CH₃ CN and the mixture was cooledto 1.C by an ice water bath. S₂ Cl₂ (33.8 grams) was added dropwise overa period of about 60 minutes. The resulting batch was then allowed towarm to room temperature gradually and kept under a gentle N₂ sweepovernight.

The batch was transferred to a round-bottom flask and the acetonitrilewas stripped in vacuum at 70° C. The resulting material was dissolved inpentane --CHCl₃ (small amount) and the solution was washed with watertwice. The solution was then dried over Na₂ SO₄, filtered, and strippedof solvent in vacuum at 70° C. to give a brown viscous liquid (analysis:14.9% S).

EXAMPLE 5

To a 500 mL reactor were added 90 grams of a phenolic mixture accordingto Example 1, 0.1 gram Fe powder as catalyst, and 100 grams (111 wt %)of CH₃ CN. To this mixture were added 26.7 grams of S₂ Cl₂ slowly atroom temperature over a period of 75 minutes. The temperature reached at39° C. during S₂ Cl₂ addition. After S₂ Cl₂ addition was completed, thebatch was heated and held at 45°-50° C. for 1 hour, N₂ was then allowedto blow over the batch for 30 minutes to faciliate the removal of HCl.The acetonitrile was then distilled at 70° C. under vacuum and a darkbrown liquid was obtained. The liquid was dissolved in heptane (˜100grams) and the solution was washed three times with water, dried overanhydrous Na₂ SO₄ and then filtered. Removal of solvent at 70° C. undervacuum gave a brown liquid which was filtered through a filter-aidcoated Whatman #54 paper (weight of product =106.5 grams; analysis:12.2% S).

EXAMPLE 6

To a 250 mL reactor were added 100 grams of the phenolic mixtureaccording to Example 1 and 20 grams (20 wt %) of acetonitrile and to theresulting solution was added dropwise 29.7 grams of S₂ Cl₂ at roomtemperature. The addition of S₂ Cl₂ was completed in about 1 hour andthe batch temperature reached 37° C. The resulting batch was then heldat 50°-55° C. for 1 hour and the acetonitrile was then vacuum strippedfrom 55°-70° C. After stripping for about 1 hour, process oil #5 (12.8grams) was added to the batch and the diluted batch was filtered througha Whatman #54 paper. A clear brown viscous liquid (115 grams) wasobtained.

EXAMPLE 7

To a 250 mL reactor were added 89.8 grams of the phenolic mixtureaccording to Example 1 and 22.5 grams (25 wt %) of CH₃ CN and to thesolution were added 26.7 grams of S₂ Cl₂ dropwise at room temperature.The batch temperature reached 44° C. due to the exotherm. The additionwas completed in about 20 minutes. The resulting batch was held at50°-55° C. for 30 minutes. The acetonitrile was distilled under vacuumfrom 55° -70° C. and held at the 70° C. for 1 hour. To the strippedmaterial was added process oil #5 (11.5 g) and the resulting batch wasstripped at 80° C. for 30 minutes to remove some crystalline solidformed in the reaction (weight of product =103.7 grams; analysis: 11.1%S, 1.46% Cl).

COMPARISON

To a 250 mL reactor were added 95.2 grams of the phenolic mixtureaccording to Example 1 and 9.6 grams (0 wt %) of CH₃ CN and to thesolution were added 28.3 grams of S₂ Cl₂ dropwise over a period of about30 minutes. The resulting batch was held at 50° to 55° C. for 30 minutesand the acetonitrile wa then vacuum-distilled from 55° to 70° C . Thebatch was held at 70° C. under vacuum for 1 hour. To the resulting batchwas added process oil #5 (12.2 grams) and the diluted product wasfiltered to give a brown liquid product (110 grams; analysis: 11.3% S,8% Cl).

COPPER CORROSION TEST (D-130)

Lubricant compositions of a full formulated 5W-30 crankcase lubricantoil containing 0.75 weight percent of the products prepared in Examples6 and 7, along with the product prepared in the comparison synthesisusing only 10 wt percent of polar modifier based on the amount ofphenols, were prepared and tested in the D-130 test as described inExample 1. The results are given in Table II below:

                  TABLE II                                                        ______________________________________                                                    Wt %       % Additive                                             Additive    Acetonitrile                                                                             in Oil      D-130                                      ______________________________________                                        Comparison  10         0.75        Moderate                                                                      Deposit                                    Ex 6        20         0.75        lb/trace                                                                      deposit                                    Ex 7        25         0.75        lb                                         ______________________________________                                    

According to the test results, the oil containing the additive preparedusing a polar modifier at 10 wt percent produced a deposit on the copperstrip which could not even be rated for corrosion and represented anunsatisfactory result. The oil containing the additive of Example 6prepared at the 20 wt percent modifier level gave a passing lb coppercorrosion result with a trace deposit. Example 7 at the 25 wt percentmodifier level gave a lb result with no deposit. Accordingly, aneffective amount of modifier is above about 10 wt percent of thephenols.

We claim:
 1. A fuel composition comprising a liquid fuel and from about0.05 to 5.0 weight percent of a liquid, sulfur-bridged hindered phenolproduct prepared by the process comprising reacting a liquid mixture ofphenols, which mixture contains at least two different hindered phenolseach phenol having at least one hydrogen in the ortho or para position,with a sulfur chloride, in amounts of from about 0.45 to 0.55 mole ofsulfur chloride per mole of phenol, in the presence of an amount of anitrogen containing polar modifier which is effective to reduce thecopper corrosion properties of said product and recovering the liquid,sulfur-bridged hindered phenol product.
 2. The fuel composition of claim1 wherein said liquid mixture of phenols contains at least two hinderedphenols which are each present in from about 5 to 95 weight percentbased on the weight of said liquid mixture of phenols.
 3. The fuelcomposition of claim 2 wherein said liquid mixture of phenols includesat least about 50 weight percent of a di-ortho, branched chain C₃ -C₁₂alkyl phenol.
 4. The fuel composition of claim 1 wherein the liquidmixture of phenols includes from about 5 to 95 percent by weight of2,6-di-tert-butylphenol, from about 5 to 95 percent by weight of2-ortho-tert-butylphenol and the polar modifier is acetonitrile.
 5. Thefuel composition of claim 4 wherein the liquid mixture of phenolscontains at least about 50 weight percent of 2,6-tert-butylphenol andthe acetonitrile is present in an amount of from abut 15 to 150 weightpercent based on the weight of said liquid mixture of phenols.